Method for treating a process gas flow containing co2

ABSTRACT

From the CO 2 -containing stream of process gas obtained in a process for the treatment of a CO 2 -containing stream of process gas, which is obtained in the production of pure synthesis gas from raw gas in the partial oxidation of heavy oils, petroleum coke or wastes, or in the gasification of coal, or when processing natural gas or accompanying natural gas, CO 2  is removed physisorptively or chemisorptively, and the solvent loaded with CO 2  is expanded to a lower pressure for the desorption of CO 2 . In order to generate CO 2  as pure as possible, the contaminated CO 2  is condensed to at least 60 bar[a] or below its critical temperature to at least 70 bar[a], and the impurities contained in the liquid CO 2  are removed by stripping with gaseous CO 2  guided in counterflow.

This invention relates to a process for the treatment of a CO₂-containing stream of process gas, which is obtained in the production of pure synthesis gas from the raw gases of the partial oxidation of heavy oils, petroleum coke or wastes, or in the gasification of coal, or when processing natural gas or accompanying natural gas, from which process gas stream CO₂ is removed physisorptively or chemisorptively, the solvent loaded with CO₂ is expanded to a lower pressure, and CO₂ is desorbed.

The processes known under the names Rectisol®, Purisol®, Selexol®, aMDEA® and hot potash washing serve the production of pure synthesis gas from the raw gases of the partial oxidation of heavy oils, petroleum coke or wastes, or from the gasification of coal or from the processing of natural gas or accompanying natural gas.

In the Rectisol® process, raw gas from the partial oxidation of heavy oils, petroleum coke or wastes, or from the gasification of coal, is used as starting material. Beside the desired product components H₂ and CO, the raw gas contains CO₂, H₂O, H₂S, CS₂, COS, HCN, NH₃, organic sulfur compounds, metal carbonyls and hydrocarbons as undesired product components which must be separated, for which purpose cold methanol is used as physical solvent. Subsequently, the absorbed product components are desorbed again by pressure reduction and boiling off the solvent and treated in processing plants. Since the solubilities of the undesired product components in cold methanol are very different, a selective separation of the product components, for instance of H₂S and CO₂, is possible. The cooled raw gas is supplied to an H₂S absorber operating with a pressure of 30 to 60 bar[a] and with cold CO₂-loaded methanol, in whose prewashing stage impurities such as HCN and NH₃ initially are removed. In the second stage of the H₂S absorber, H₂S and the other sulfur compounds are absorbed, so that the residual sulfur content is <0.1 ppm. The loaded methanol leaving the H₂S absorber is expanded to a medium pressure, and the gases H₂ and CO desorbed thereby are recirculated into the raw gas. Subsequently, the methanol is heated to boiling temperature and “boiled off”; in the process, all absorbed gases are released, and the gas rich in H₂S is charged to a Claus plant for recovering sulfur. Part of the CO contained in the synthesis gas free from sulfur is converted to CO₂, so that the CO₂ concentration typically rises to about 33%. Subsequently, the cooled gas is supplied to a two-stage CO₂ absorber. The loaded methanol discharged from the CO₂ absorber is expanded to a lower pressure and cooled thereby. The CO₂ released thereby is free from sulfur and can either be discharged to the atmosphere or be used e.g. for the production of urea. The synthesis gas obtained in the CO₂ absorber with a CO₂ concentration of about 3% is introduced into the methanol synthesis. In the Purisol® process, N-methyl-2-pyrrolidone (NMP) is used as physical solvent instead of methanol. The CO₂ from the raw gas is expanded into the gas turbine by performing work.

In the aMDEA® process, the raw gas to be treated enters at the bottom of an absorption column with a structured or dumped packed bed, in which the raw gas is countercurrently washed with a cooled aqueous solution of methyldiethanolamine (MDEA) supplied at the top of the absorption column, which contains an activating agent (a) for increasing the yield of CO₂. At the top of the absorption column, the purified gas is withdrawn. The aMDEA solution loaded with CO₂ and H₂S, which is discharged at the bottom of the absorption column, can either be heated directly or upon expansion to a lower pressure. As heat source, hot regenerated aMDEA solution from the regeneration column is used. In the regeneration column, the loaded aMDEA solution is regenerated completely by reheating and upon cooling is recirculated to the top of the absorption column. At the top of the regeneration column, a gas stream containing CO₂ and H₂S is withdrawn. The separated gas rich in H₂S is supplied either to a Claus plant or to a postcombustion. The different reaction rates of the amines for H₂S and CO₂ form the basis for a selective absorption of H₂S and for the separation of CO₂.

The disadvantage of the above-mentioned physisorptively and chemisorptively operating absorption processes for removing the undesired components CO, H₂O, H₂S, COS, HCN, NH₃, organic sulfur compounds, metal carbonyls and hydrocarbons contained in the raw gas from the partial oxidation of heavy oil, petroleum coke and wastes, from the gasification of coal and from the processing of natural gas and accompanying natural gas consists in that the CO₂ produced still contains 0.1 to 20 vol-%, in particular 0.5 to 2.5 vol-%, of one or more of the components N₂, CO, H₂ and CH₄ and therefore is not suitable for a number of applications.

It is the object of the present invention to develop the process described above such that the CO₂ obtained from a raw gas by means of a physisorptively or chemisorptively operating absorption process has a purity as high as possible and can directly be used as valuable product; in particular, the CO₂ should meet the quality requirements for compaction in petroleum deposits for an improved oil recovery while at the same time finally storing the CO₂ in the petroleum deposits.

This object is solved in that the CO₂ contaminated with a total of 0.1 to 20 vol-%, preferably 0.5 to 10 vol-%, in particular 0.5 to 2.5 vol-% of one or more of the components N₂, CO, H₂ and CH₄ is condensed at room temperature to a pressure of at least 60 bar[a] or below the critical temperature of CO₂ of 31° C. to at least 70 bar[a] and the CO₂-containing gaseous impurities obtained thereby, which chiefly have a liquid condition, are removed by stripping the CO₂ with gaseous CO₂ used as stripping gas, and CO₂ is obtained as a liquid. During stripping, the impurities are removed from the liquid CO₂ by passing through the stripping gas against the flow direction of the liquid CO₂ and are transferred into the stripping gas, since the vapor pressure of the impurities to be removed from the liquid CO₂ is greater than in the stripping gas and therefore a transfer is effected from the liquid CO₂ into the stripping gas.

In accordance with this aspect of the process, the CO₂ is condensed to a pressure of 10 to 30 bar[a] and cooled to a temperature of −40 to −5° C.

For generating the stripping gas, a corresponding amount of the liquid CO₂ present in the bottom of the column is evaporated continuously.

The stripping gas containing the impurities is expelled at the top of the stripping column and recooled in accordance with a further feature of the invention, in order to condense at least part of the CO₂ out of the stripping gas and recirculate the same to the bottom of the stripping column.

One aspect of the invention consists in that the loaded stripping gas is introduced into the absorption stage of the process.

The process of the invention will subsequently be explained in detail by means of an embodiment in conjunction with a basic flow diagram illustrated in the drawing.

From raw gas obtained by partial oxidation of heavy oil, the undesired components CO₂, H₂O, H₂S, COS, HCN, NH₃, organic sulfur compounds, metal carbonyls, C_(n)H_(m) and further impurities, such as resin formers and mercaptans, are absorbed by the Rectisol® process, typically by using methanol. By adding steam, a large part of the CO of the synthesis gas largely purified from undesired components and impurities by the Rectisol® process is catalytically converted to CO₂ and further H₂.

The CO₂ still containing a total of 2.0 vol-% of N₂, CO, H₂ and CH₄ as impurities is separated from the purified synthesis gas and via conduit (1) charged to a compressor (2), in which the CO₂ is condensed to a pressure of 25 bar[a], and subsequently supplied via conduit (3) to a cooling plant (4), in which the CO₂ is cooled to a temperature of −25° C. Under these conditions, the CO₂ is almost completely transferred into the liquid condition, whereas the components contaminating the CO₂ remain gaseous almost completely. Via conduit (5), the liquid CO₂ is supplied to the top of a stripping column (6) and in counterflow with gaseous CO₂ used as stripping gas is passed through the stripping column (6), in whose bottom the stripping gas is generated by evaporating a small amount of liquid CO₂ by means of a suitable heat source (7). By means of the stripping gas, the impurities are removed from the liquid CO₂ and transferred into the gaseous CO₂. At the bottom of the stripping column (6), liquid pure CO₂ is withdrawn via conduit (8). The stripping gas containing the impurities, which is withdrawn at the top of the stripping column (6), can be supplied via conduit (9) to a cooling plant (10), in which part of the CO₂ is condensed. The remaining stripping gas loaded with the impurities is supplied to the raw synthesis gas via conduit (11). If the CO₂ content of the remaining amount of stripping gas is too high and hence a recirculation of the raw synthesis gas is uneconomic, the stripping gas can be recirculated into the process, for instance into the Rectisol® process, for the production of pure synthesis gas and can be completely liberated from CO₂ by absorption in a suitable absorption column together with the expansion gas stream of the process to be recirculated. As a cooling plant for liquefying the CO₂, there can also be employed the cooling plant used in connection with this process. Moreover, there is a possibility for cold exchange with corresponding streams of the process.

The data for the temperatures, pressures and composition of the substance streams as determined with a practical embodiment of the invention are indicated in the following table with reference to the basic flow diagram illustrated in the drawing:

Conduit 1 3 5 8 9 Temperature 20 20 −25 −25 −25 (° C.) Pressure (bar[a]) 1 25 25 25 25 Composition vol-% (calculated dry) N₂ 1.0 1.0 1.0 traces 16 H₂ 0.5 0.5 0.5 traces 8 CO 0.5 0.5 0.5 traces 8 CH₄ 3.0 3.0 3.0 traces 48

The advantages achieved with the invention in particular can be seen in that virtually the entire CO₂ is obtained in pure form and the losses of the valuable gases CO, H₂ and CH₄ are reduced to zero. 

1. A process for the treatment of a CO₂-containing stream of process gas, which is obtained in the production of pure synthesis gas from raw gas obtained in the partial oxidation of heavy oils, petroleum coke or wastes, or in the gasification of coal, or when processing natural gas or accompanying natural gas, from which process gas stream CO₂ is removed physisorptively or chemisorptively, the solvent loaded with CO₂ is expanded to a lower pressure, and CO₂ is desorbed, wherein the CO₂ contaminated with a total of 0.1 to 20 vol-% of one or more of the components N₂, CO, H₂ and CH₄ is condensed at room temperature to a pressure of at least 60 bar[a] or below the critical temperature of CO₂ of 31° C. to at least 70 bar[a] and the CO₂-containing impurities obtained thereby, which have a liquid condition, are removed by stripping the CO₂ with gaseous CO₂ guided in counterflow.
 2. The process according to claim 1, wherein the CO₂ is condensed to a pressure of 10 to 30 bar[a] and is cooled to a temperature of −40 to −5° C.
 3. The process according to claim 1, wherein CO₂ contaminated with a total of 0.5 to 10 vol-% of one or more of the components N₂, CO, H₂ and CH₄ is used.
 4. The process according to claim 1, wherein the stripping gas loaded with one or more of the components N₂, CO, H₂ and CH₄ is added to the raw gas.
 5. The process according to claim 1, wherein part of the stripping gas loaded with one or more of the components N₂, CO, H₂ and CH₄ is condensed, the condensate is recirculated to the bottom of the absorption column, and the remaining stripping gas is added to the raw gas.
 6. The process according to claim 1, wherein the stripping gas loaded with one or more of the components N₂, CO, H₂ and CH₄ is introduced into the absorption stage of the process. 